Polysoude Equipment

TIG Cold Wire, Hot Wire, MIG/MAG and Plasma

For orbital and mechanised welding

Closed Welding Heads
Specifically designed for the welding of thin wall tubes made from stainless steel, titanium, Inconel etc. in a range of diameters from 6 to 170 mm. Welding of tubes and fittings. Closed gas chamber to avoid oxidation. A compact design for use in areas with limited access. Butt welding without filler wire up to approx. 3 mm wall thickness.

UHP
Ultra High Purity. Special gas distribution to avoid particle emissions. Modular clamping system for fast adaptation to different diameters. Fixture Blocks for perfect alignment of fittings are available

MW
For high productivity applications. High duty cycle due to water cooling. Adaptation kit for welding of accessories such as elbows, flanges, valves, connections

Open Welding Heads

For all orbital welding applications, with or without wire (cold or hot wire), for workshop and on-site use. MU IV welding heads for a range of diameters from 8 to 275 mm. Polycar for large diameter tubes and pipes from 114 mm onwards. High duty cycle due to water cooling. Modular design for easy adaptation to different tube geometries. High productivity with TIG - Hot Wire and MIG/MAG welding process.

AND OrbITAl WelDING

MU IV
For standard applications with continuously adjustable clamping system

MU IV AVC/OSC HW Hot Wire

Arc Voltage Control (AVC) and Torch Oscillation Control (OSC)

POLYCAR
For large diameter tubes and pipes. Carriage welding head with guide ring, Arc Voltage Control (AVC) and Torch Oscillation Control (OSC)

Tube to Tubesheet Welding Heads

For welding with or without filler wire. TS heads for a range of diameters from 6 to 60 mm. Arc Voltage Control (AVC) available on TS 2000. High duty cycle due to water cooling.

TS 25

TS & TS 34
Compact closed welding heads for flush tubes. Closed gas chamber to avoid oxidation. Centering and clamping by means of an expanding mandrel.

TS 2000 & TS 8/75

TS 2000
Open welding head, designed for flush tubes, protruding tubes and recessed tubes, back plate, header box and internal welding. External or integrated wire feeder, with or without Arc Voltage Control (AVC)

TS 34

Polyfil -3
External wire feeder for 15 kg spools

TS 8/75

MeCHANISeD

Solutions for Mechanised and Automated Welding

It is the welding process that determines the characteristics of the tool for each application, thus ensuring optimum implementation. Polysoude developed and enhanced a range of generic and modular tools which we use for customer applications.

Mechanised welding
Mechanised welding systems TIG - Cold Wire, Hot Wire, MIG/MAG, Plasma

Cladding
Automated cladding systems, TIG - Cold Wire, Hot Wire

POWer SOurCeS

Power Sources for Automated Welding TIG - Cold Wire, Hot Wire, MIG/MAG, Plasma
Welding sequences entirely programmable in welder language. Intuitive operator interface. Integrated programme library - ready to weld. Real time monitoring system.
PC 300 A PC 350 A PC 600 A PC MIG/MAG

PC Series

for orbital and automated welding PC programming. For all applications. TIG - Cold Wire, Hot Wire, MIG/MAG, Plasma. 300 to 600 A, modular design for perfect adaptation to your application. Interface for mechanised and robotic peripherals, three-phase power supply

PS 164-2
160 A, all inclusive, portable, single-phase power supply

P4
170 A, modular, portable programming by PC or touch screen, single-phase power supply

PS 406-2
400 A, all inclusive, with AVC and OSC, three-phase power supply

P6 & P6 HW Hot Wire

300 A Cold Wire and 520 A/140 A Hot Wire, all applications programming by PC or touch screen, with AVC and OSC, three-phase power supply

MU IV
TIG With or without Filler Wire, AV C , OSC

Open Welding Head for welding of tube to tube joints, tube to elbow joints

THE ART OF WELDING

MU IV
Advantages
Productivity increase of more than one third Easy to use Challenging applications, even with delicate materials, can be welded Quick to set-up according to the workload making variations in production capacity trouble free Precision engineered assemblies for a lifetime of trouble-free service Resulting from 50 years experience in mastering welding technologies

Open Welding Head

for welding of tube to tube joints, tube to elbow joints

General Characteristics
Encoder for position based control of the welding program

A range of modular standard welding heads, perfectly adapted to your needs

Two interchangeable clamping systems (C and P): C Clamp shells per O.D., for precise and strong clamping, for heavy duty production, with water cooling for preheated tubes
MU IV for use with external wire feeder

Closed loop water cooled welding torch

Mechanical sensor for a constant distance between electrode and workpiece

Closed loop regulation to ensure precise, constant or pulsed welding speed

P full range adjustable for frequent O.D. change

Welding torch with ceramic nozzle and gas lens for laminar gas protection

Drive motor with angle gearbox for reduced axial clearance

MU IV with integrated wire feeder

2-axis wire adjustment

Motorized Arc Voltage Control (AVC) and Torch Oscillation Control (OSC) for multi-pass welding of medium and heavy wall tubes

Precise and constant torch rotation by means of planetary drive On-board wire feeder module for 1,5 kg spool or floor mounted POLYFIL with 15 kg spools

MU IV with AVC/OSC

160 A, all inclusive, portable, single-phase power supply

170 A, modular, portable, programming by PC or touch screen, single-phase power supply

400 A, all inclusive, with Arc Voltage Control (AVC) and Torch Oscillation Control (OSC), three-phase power supply

300 A, all applications, programming by PC or touch screen, with Arc Voltage Control (AVC) and Torch Oscillation Control (OSC), three-phase power supply

Wire Feeder

Associated Power Sources

PS 164-2

P4

PS 406-2

P6

Polyfil-3
External wire feeder and other integrated wire feeders

Technical Specification
Cable length: 9 m
Type MU IV Min. / Max. Double clamping system recommended / / / / / / / / / / 8 to 28 8 to 38 19 to 64 19 to 80 19 to 104 25 to 115 25 to 128 / / / Double clamping system recommended / / / / / / / / / 8 to 38 19 to 64 19 to 80 / / 25 to 128 / / / A 116 126 155 172 204 215 240 410 470 500 116 126 155 172 204 215 240 410 470 500 A 142 184 200 222 235 340 410 500 530 142 184 200 222 235 340 410 500 530 B 23 16 16 16 16 16 16 16 16 23 16 16 16 16 16 16 16 16 Dimensions in mm B 16 16 16 16 16 16 16 30,5 30,5 30,5 16 16 16 16 16 16 16 30,5 30,5 30,5 C 5 5 5 5 5 5 5 14 14 14 5 5 5 5 5 5 5 14 14 14 Amplitude Ca 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 Cb 20 20 20 20 20 30 30 30 30 20 20 20 20 20 30 30 30 30 D 96 96 98 97 90 101 99 158,5 174,5 172,5 79 79 88 88 90 92 108 178 180 178,5 D 150 136 136 140 139 134 165 179 179 130 128 126 128 128 143 185 184 184 E 70 72 93 103 121,5 148 173 208 254 276 70 72 93 103 121,5 148 173 208 254 276 E 72 93 103 121,5 148 173 208 254 276 72 93 103 124,5 148 173 208 254 276

O.D. independent adjustable clamping O.D. O.D. related shell clamping O.D. independent adjustable clamping O.D. O.D. related shell clamping

MU IV 14/28 P * MU IV 8/38 P MU IV 19/64 P * MU IV 19/80 P MU IV 19/104 P * MU IV 25/115 P MU IV 25/128 P * MU IV 76/195 P MU IV 101/245 P * MU IV 114/275 P MU IV 14/28 C * MU IV 14/38 C * MU IV 30/64 C * MU IV 30/80 C * MU IV 44/104 C * MU IV 50/115 C * MU IV 50/128 C * MU IV 76/195 C * MU IV 101/245 C * MU IV 114/275 C * MU IV AVC, OSC Min. / Max. MU IV 8/38 P MU IV 19/64 P * MU IV 19/80 P MU IV 30/104 P* MU IV 42/115 P MU IV 42/128 P* MU IV 76/195 P MU IV 101/245 P* MU IV 114/275 P MU IV 14/38 C * MU IV 30/64 C * MU IV 30/80 C * MU IV 44/104 C * MU IV 50/115 C * MU IV 50/128 C * MU IV 76/195 C * MU IV 101/245 C * MU IV 114/275 C *

B C / Cb D

Ca

> A/2

* on request P Adjustable clamping system C Adjustable clamping system

Options and Accessories

On board wire feeder module for 1,5 kg spool or floor mounted POLYFIL with 15 kg spools Clamp shells (C-clamping system) for all tube and pipe O.D.s Extension cable (15 m) Dual welding head switch box Compact brief-case for transport and storage Tungsten electrodes, pre-sharpened and pre-cut

Adapting to all your applications !

As working conditions are better than in manual welding, a welding operator accomplishes on average 30% more welds per day.

MU IV 195 HW
TIG Hot Wire, AV C , OSC

Hot Wire Welding Head for welding of tubes and pipes

THE ART OF WELDING

Hot Wire Welding Head

Highest flexibility and productivity

MU IV 195 HW

General Characteristics
Rotation clutch device for quick cable winding

for multipass TIG welding of tubes and pipes

Motorised Arc Voltage Control (AVC) and Torch Oscillation Control (OSC) for multipass welding of medium wall thicknesses

Quick clamping system for all situations: Grip-it

Advantages
Simplified handling and adjustment Outer diameter range: 76 to 195 mm (3" to 7.7") Welding head clamps only on one side of the weld joint Closed loop water cooling for highest duty cycle

Particularly designed for high duty applications by means of high temperature resistant materials and closed loop water cooling
Welding head: one-size-fits

Closed loop regulation to ensure precise control of the welding speed and wire feeding

Reinforced cable-hose assembly Resulting from over 50 years experience in mastering welding technologies Integrated wire feeder
Quick change of the electrode

Technical Specification
Outside diameters Diameter range Torch Type Cooling Special TIG troch with extra large gas lens Closed loop water cooling 1500 mm/min - 59.1 in/min 20 mm - 0.8" Stepper motor Polyfil Auto 7929 HW 7929 mm/min - 312.2 in/min 1,5 kg - 3.3 lbs / 0,8 mm - 0.03" 9 m - 29.53 ft 15 kg - 33.07 lbs See drawings 76 to 195 mm - 3" to 7.7"

Dimensions A B C D E F G 560 mm 26.5 mm 137 mm 205 mm 201 mm 100 mm 642 mm 22.0" 1.0" 5.4" 8.1" 7.9" 3.9" 25.3"

AVC (Arc Voltage Control) and OSC (Torch Oscillation Control) Maximum travel speed Stroke Motor Wire feeder Type Maximum wire feeding speed Spool weight / recommended wire diameter Dimensions and weight Cable length Weight (excl. cable) Dimensions of the welding head

Associated Power Sources

P6 HW
520 A welding current, 140 A Hot Wire current, all applications programming by PC or touch screen, with Arc Voltage Control (AVC) and Torch Oscillation Control (OSC), three-phase power supply

PC 600 HW
600 A welding current, 140 A Hot Wire current, modular design for perfect adaptation to your application. Interface for mechanised and robotic peripherals, three-phase power supply

Options and Accessories

Angle gear box Tool kit for daily operation C version with water cooled clamp shells Extension cable (15 m - 49.21 ft) Tungsten electrodes, pre-sharpened and pre-cut Balancer Compact shipping case for transport and storage

MW
TIG Without Filler Wire

Closed Chamber Welding Head for welding of tube to tube joints

THE ART OF WELDING

MW

Closed Chamber Welding Head

for welding of tube to tube joints

General Characteristics
Off-set electrode holder

Easy to use, highest quality and productivity

Reversible hook for an enlarged range of clamping tolerances

Gas seal

Return-to-home feature: the electrode gear automatically returns to its loading position

Elbow kit

Advantages
Oxidation-free welds Optimised ergonomics, easy to use High duty cycle Respecting international standards and norms (EHEDG, ASME, FDA...) Compatible with all Polysoude Power Sources Resulting from 50 years experience in mastering welding technologies Closed loop regulation to ensure precise, constant or pulsed welding speed Narrow welding head profile for use in areas with constrained axial and radial clearance Interchangeable flexible titanium Tube Clamp Inserts TCIs. Comply with standard tube O.D. sizes and tolerances, for hygienic and high purity requirements Particularly designed for high duty cycle applications by means of high temperature resistant materials and closed loop water cooling

Flexible Titanium Tube Clamp Inserts -TCIs

Encoder for position based control of the welding program

Reinforcement bars

Remote control

Integrated remote control

Associated Power Sources

PS 164-2
160 A, all inclusive, portable, single-phase power supply

P4
170 A, modular, portable, programming by PC or touch screen, single-phase power supply

The Complete Range

MW 40

MW 65

MW 115

MW 170

Technical Specifications
Type Tube O.D. in mm / inches from - to MW 40 MW 65 MW 115 MW 170 6 - 40 mm 12 - 65 mm 25 - 115 mm 80 - 170 mm 1/4 1/2 1 1 1/2 A 100 126 200 290 B 430 458 547 580 Electrode off-set Type 1 5 mm 2 11 mm Max. tube O.D. in mm / inches MW 40 MW 65 MW 115 MW 170 33,7 mm 60,3 mm 114,3 mm / 1 - 5/16" 2 - 3/8" 4 - 1/2" / 19,05 mm 42,4 mm 101,6 mm / 3/4" 1 - 21/32" 4" / / / / 168,3 mm / / / 6- 5/8" 3 5 mm Dimensions in mm C 38 38 46 63 D 19 19 23 31,5 E 50 63 100 145 Net weight in kg 6 7 9 18

- 2 1/2 - 4 1/2

3 1/8 - 6 5/8

Cable length: 5,5 m

A E O.D.

Options and Accessories

Titanium Tube Clamp Inserts TCIs for all tube and pipe O.D.s, available both in metric and imperial sizes Elbow-kit with off-set electrode holder, single sided tube clamping and gas seal, designed for fittings or components with short stick-out Extension cable (15 m) Dual welding head switch box Compact brief-case for transport and storage Tungsten electrodes, pre-sharpened and pre-cut

Adapting to all your applications !

Learning to use the equipment took me less than one day of training.

TIG

With

TS 8/75
or Without Filler Wire, AV C

Open Welding Head for welding of tube to tubesheet joints

THE ART OF WELDING

TS 8/75
Advantages
More compact: Reduced space and weight More ergonomic: double handle with integrated remote control for clamping and welding More productive: simultaneous use of multiple welding heads with pneumatic clamping by one operator More automatic: Standard version with AVC (Arc Voltage Control) More simple: simplified mechanical adjustments, in particular, filler wire positioning More precise: on board filler wire for constant wire feeding and accurate wire impact position Resulting from 50 years experience in mastering welding technologies

for welding of tube to tubesheet joints

Open Welding Head

General Characteristics
Fixed or rotating on board filler wire

Cutting-edge design using the very latest materials and engineering technologies
Optional: Centering Shafts and Mandrels for specific tube diameters Designed for high duty cycle applications with high temperature resistant materials and closed loop water cooling

Different types of weld joint configurations:

A wide variety of tooling is available to accommodate all existing tube sheet joint designs

Endless rotating torch with no cable winding by means of a unique collector to supply the torch with welding current, shielding gas and cooling liquid

Protruding tube welding

Clamping/ centering mandrel for all tube I.D.s

Standard version with pneumatic clamping/ centering system

Motorized Arc Voltage Control (AVC) or programmable electrode height Closed loop regulation to ensure precise, constant or pulsed welding speed

Flush tube welding

Recessed tube welding

Torch with ceramic nozzle and diffuser for laminar gas protection

Encoder for position based control of the welding program

Back plate tube welding

Return-to-home feature: the electrode automatically returns to its starting position Simplified wire guide Adjustable stand-off legs for every pitch

Integrated remote control in handle, for clamping and welding

Double plate - header box welding

Internal tube welding

300 A, all applications, programming by PC or touch screen, with Arc Voltage Control (AVC), three-phase power supply

Wire feeder

Associated Power Sources

P6

Polyfil-3
External wire feeder for 15kg spools

Adapting to all your applications !

The most efficient and fastest way to produce all your tube sheet welds!

Technical Specification
Min. tube I.D. Max. tube O.D. Duty cycle (air cooled torch) 8 mm (0.315") 75 mm (2.95") (O.D.s > 60 mm on request) 250 A / 60 % Option: water cooled torch Closed loop, water Stroke 20 mm For tube I.D. from 15 to 40 mm For tube I.D. from 10,5 to 60 mm Rotating on board wire feeder 1,5 kg / 4" 15 kg / 300 mm standard 2 mm max 13 mm max

Cooling of welding head

Arc Voltage Control (AVC) or alternatively manual adjustment of distance electrode - work piece Central pneumatic clamping/ centering system Basic centering mandrel Wire feeder (on board or floor mounted) Wire spool diameter on board floor mounted Tube joint designs: flush recessed protruding internal bore welding back plate - header box welding Weight Cable length standard
option

7 kg (excl. cable and wire spool) 9m

B C

Dimensions in mm
Basic centering mandrel Pneumatic clamping/ centering mandrel

A B C D E F

205 417 148 161 202 583

205 443 148 161 202 583

F E

Options and Accessories

Clamping/ centering mandrels for all tube I.D. s On board wire feeder (fixed or rotating) for precise and constant wire feeding Central (located in the tube to be welded), pneumatic clamping/ centering system for improved quality and productivity Accessories for all types of applications Extension cable (15m) Dual welding head switch box (without AVC) Compact shipping-case for transport and storage Tungsten electrodes pre-sharpened and pre-cut Tooling

TS 25
TIG Without Filler Wire

Closed Chamber Welding Head for welding of tube to tubesheet joints

THE ART OF WELDING

TS 25

Closed Chamber Welding Head

for welding of tube to tubesheet joints
Purge gas chamber for oxidation-free welding, particularly in the case of titanium, Inconel etc.

General Characteristics

Easy to use, highest quality and productivity

Interchangeable expansion / centering mandrel for all tube I.D.s

Endless rotating torch, no cable wrap-up by means of a unique collector to supply the welding head with welding current, shielding gas and cooling liquid

Welding head designed for flush tube welding

Manual clamping

Advantages
Productivity increase of more than one third Easy to use Instant adapation to workload variations by simultaneous use of multiple welding heads High quality, oxidation-free welds Resulting from 50 years experience in mastering welding technologies Closed loop regulation to ensure precise, constant or pulsed welding speed Return-to-home feature: the electrode automatically returns to its starting position Encoder for position based control of the welding program

Laminar diffusion of the protection gas inside the purge gas chamber

Centering and clamping by means of an interchangeable mandrel

Associated Power Sources

PS 164-2
160 A, all inclusive, portable, single-phase power supply

P4
170 A, modular, portable, programming by PC or touch screen, single-phase power supply

P6
300 A, all applications, programming by PC or touch screen, with Arc Voltage Control (AVC) and Torch Oscillation Control (OSC), three-phase power supply

Adapting to all your applications !

We gained, on average, 35% more welds per day.

Technical Specification
Min. tube I.D. Max. tube O.D. Duty cycle Torch cooling Tube joint design: flush recessed protruding internal bore welding Positioning / centering Purge gas chamber Weight
standard
option

10 mm 25,4 mm for other dimensions, please consult us 120 A / 20 % 70 A / 50 % Closed loop, water

1 mm max 0,5 mm max Expansion mandrel

1,5 kg (excl. cable)

Cable length: 9 m

C A
Dimensions in mm A 63 B 116,5 C 41,5 D 330 E 31.5

Options and Accessories

Expansion / centering mandrels for all tube I.D.s Dual welding head switch box Compact shipping case for transport and storage Tool kit for daily operation Extension cable (15 m) Tungsten electrodes, pre-sharpened and pre-cut

TS 34
TIG Without Filler Wire

Closed Chamber Welding Head for welding of tube to tubesheet joints

THE ART OF WELDING

TS 34
Expansion / centering mandrel for all tube I.D.'s

Closed Chamber Welding Head

for welding of tube to tubesheet joints

General Characteristics
Endless rotating torch, no cable wrap-up by means of a unique collector to supply the welding head with welding current, shielding gas and cooling liquid

Easy to use, highest quality and productivity

Pneumatic clamping option

Particularly designed for high duty cycle applications by means of high temperature resistant material and closed loop water cooling

Laminar diffusion of the protection gas inside the purge gas chamber

Manual clamping

Flush tube welding (purge gas chamber)

Flush tube welding (torch with diffuser)

Advantages
Productivity increase of more than one third Easy to use Instant adapation to workload variations by simultaneous use of multiple welding heads High quality level, oxidation-free welds Resulting from 50 years experience in mastering welding technologies

Purge gas chamber for oxidation-free welding of titanium, Inconel etc.

Back plate tube welding

Return-to-home feature: the electrode automatically returns to its starting position Integrated remote control in handle

Closed loop regulation to ensure precise, constant or pulsed welding speed

Encoder for position based control of the welding program

Nipple on header

Associated Power Sources

PS 164-2
160 A, all inclusive, portable, single-phase power supply

P4
170 A, modular, portable, programming by PC or touch screen, single-phase power supply

P6
300 A, all applications, programming by PC or touch screen, with Arc Voltage Control (AVC) and Torch Oscillation Control (OSC), three-phase power supply

Adapting to all your applications !

On our site, an operator uses 2 or 3 welding heads simultaneously.

Technical Specification
Min. tube I.D. Max. tube O.D. Duty cycle Torch cooling Tube joint designs: flush recessed protruding internal bore welding Positioning / centring Purge gas chamber Weight
standard
option

10 mm 33,7 mm for other dimensions, please consult us 120 A max 120 A / 75 % Closed loop, water

1 mm max 0,5 mm max Expansion mandrel

3,8 kg (excl. cable)

Cable length: 9 m
A ID B C D G H F

E
B ID J

C D G
H

F
E

Dimensions in mm
A TS 34 TS 34
+ Pneumatic clamping system

B 49 154

C 63 63

D 123 123

E 235 285

F 144.5 197

G 80
According to application

H 48 100,5

IDmin 9,5 12

IDmax 32 28

70 116

96

273

Options and Accessories

Expansion / centring mandrels for all tube I.D.'s Pneumatic expansion / centring device Dual welding head switch box Compact shipping case for transport and storage Tool kit for daily operation Extension cable (15 m) Tungsten electrodes, pre-sharpened and pre-cut

POLYFIL-3
TIG

Cold Wire Feeder for orbital welding

THE ART OF WELDING THE ART OF WELDING

Polyfil-3
External Wire feeder

Cold wire feeder for orbital TIG welding.

Advantages
Compatible with all series of Polysoude power sources and welding heads Closed loop regulation to ensure precise wire feeding Directly controlled by the power source, no external power supply is required Four adjustable wire rollers Closed, protected wire spool Carry Handle

Technical Specification
Compatible for wire spool Diameter and weight
Wire liner

15 kg / 300 mm 5 kg / 200 mm 0,8 mm and 1,0 mm (other dia. on request) min 150 mm/min max 2552 mm/min 9m 620 x 300 x 450 mm 16 kg b d1 d2

d1 d2

Wire diameter Wire feed speed (valid for all PolysoudeTM power sources) Cable length Dimensions L x W x H Weight excluding wire spool

Wire spool Dimensions in mm 5 kg 57 52 200 15 kg 105 52 300

Drive mechanism

Options and accessories

Wire liner Wire drive pressure rollers for different wire diameters

POLYCAR 30 LP
TIG Cold Wire, AV C , OSC

for welding of tubes and pipes

Low Profile Open Type Carriage Welding Head

THE ART OF WELDING

Polycar 30 lP
Carriage Welding Head

General Characteristics
Top-loaded electrode providing quick and easy set up Torch with extra large ceramic nozzle and gas lens for high quality laminar gas protection Motorised Arc Voltage Control (AVC) and Torch Oscillation Control (OSC) for multipass welding
For all weldable materials (TIG)

for welding of tubes and pipes

Highest flexibility and quality

Advantages
Extremely compact for minimum radial clearance Mounting and dismounting in less than one minute Simplified handling and adjustment Especially designed to fulfil highest weld quality standards for all weldable materials (TIG), including Aluminium under DC-Helium Reproduces all movements of a manuel welder and completes the weld in a series of passes The welding head travels around the tube on a premounted guide ring Resulting from over 50 years experience in mastering welding technologies Guide rings for all tube and pipe O.D.s

LP Low Profile Version designed for use in areas with reduced radial clearance Closed loop regulation to ensure precise, constant or pulsed welding speed and wire feeding Particularly designed for high duty cycle applications by means of high temperature resistant materials and closed loop water cooling
Integrated wire feeder with mini or standard wire spool for optimised radial clearance

Technical Specification
Outside diameters Diameter range Torche Type Cooling AVC - Arc Voltage Control Maximum travel speed Travel Motor 500 mm/min - 19.7 in/min 10 mm - 0.4" Stepper motor 1000 mm/min - 39.4 in/min 10 mm - 0.4" Stepper motor On board 2000 mm/min - 78.7 in/min 0,5 or 1,5 kg - 1.1 or 3.31 lbs / 0,8 mm - 0.03" 15 m - 49.21 ft 3 kg - 6.61 lbs See drawings Special TIG torch with extra large gas lens Closed loop water cooling 32 to 168 mm - 1.3" to 6.6"

Dimensions A* B C D E 60 mm 32 mm 168 mm 200 mm 185 mm 34,5 mm 2.4" 1.3" 6.6" 7.9" 7.3" 1.4"

OSC - Oscillation Control Maximum travel speed Travel Motor Wire feeder Type Maximum wire feeding speed Spool weight / recommended wire diameter Dimensions and weight Cable length Weight (excl. cable) Dimensions of the welding head

Variable profile for various tube and pipe O.D.s

* in case of 0.5 kg (1.1 lbs) spool

Associated Power Sources

P6
300 A, all applications programming by PC or touch screen, with Arc Voltage Control (AVC) and Torch Oscillation Control (OSC), three-phase power supply

PC Series
300 to 600 A, modular design for perfect adaptation to your application. Interface for mechanised and robotic peripherals, three-phase power supply

Options and Accessories

Guide rings for all tube and pipe O.D.s Extension cable (15 m - 49.21 ft) Tool kit for daily operation Tungsten electrodes, pre-sharpened and pre-cut Compact shipping case for transport and storage

POLYCAR 60-2
TIG Cold Wire, Hot Wire, AV C , OSC

Open Type Carriage Welding Head for welding of tube and pipe joints

THE ART OF WELDING

Polycar 60-2
Open Type Carriage Welding Head

General Characteristics

for welding of tube and pipe joints

Highest flexibility and quality

Motorised Arc Voltage Control (AVC) and Torch Oscillation Control (OSC) for multi-pass welding of medium and heavy wall tubes and pipes

Quick positioning
Torch block with AVC/OSC cross slides and adjustable wire guide

Advantages
Minimal radial and axial clearance Modular design for orbital TIG Cold Wire and Hot Wire welding Perfectly adapted to tube and pipe welding of medium-sized and heavy wall thicknesses Reproduces all movements of a manual welder and completes the weld in a series of passes Especially designed for welding under difficult conditions in workshop or on site Narrow Gap Welding for further productivity increase Resulting from 50 years experience in mastering welding technologies

Particularly designed for high duty cycle applications by means of high temperature resistant materials and closed loop water cooling Encoder for position based control of the welding program Tiltable torch for socket welding ( 15 ) Torch with ceramic nozzle and gas lens for laminar gas protection
On-board wire feeder with straightening device

LP Low Profile version designed for use in areas with reduced axial clearance
Chromium guide rings for all tube and pipe O.D.s

Closed loop regulation to ensure precise, constant or pulsed welding speed

On-board filler wire module with 1,5 kg or 5 kg spool

Torch module V2 Narrow Gap, for wall thicknesses up to 75 mm

Associated Power Sources

PS 406
400 A, all inclusive, with Arc Voltage Control (AVC) and Torch Oscillation Control (OSC), three-phase power supply

P6
300 A, all applications programming by PC or touch screen, with Arc Voltage Control (AVC) and Torch Oscillation Control (OSC), three-phase power supply

PC Series
300 to 600 A, modular design for perfect adaptation to your application. Interface for mechanised and robotic peripherals, three-phase power supply

Technical Specification
Welding process / Version Tube / pipe O.D. A (min. radial clearance) AVC Arc Voltage Control OSC - Oscillation Control B (axial clearance for guide ring) C (overall axial clearance) Drive motor (AVC/OSC slides) AVC axis speed range OSC axis speed range E Torch tilting Max. welding current (A) Electrode diameter Carriage drive Welding speed range On-board wire spool diameter Wire feeder drive Wire feed range Wire diameter Welding carriage weight (excl. cable) 95 - 2068 mm / min 200 mm / 5 kg 190 / 167 mm 60 mm CW - TIG Cold Wire HW - TIG Hot Wire 168 mm / 6 190 / 167 mm 60 mm 60 mm 146,5 mm 375 to 435 mm (OSC = 60 mm) Stepper motor 10 - 500 mm / min 20 - 1000 mm / min 15 300 A 2,4 (standard) / 3,2 / 4,0 mm DC motor, closed loops 20 - 400 mm / min 200 mm / 5 kg DC motor, closed loops 360 - 7929 mm / min 0,8 mm (other dia. on request) 9 kg 95 - 2408 mm / min 100 mm / 1,5 kg 146 / 135 mm 30 mm LP - TIG Cold Wire

Cable length: 9 m

Type Amin TIG FF TIG FC TIG LP 190/167 190/167 146/135 Bmin

Dimensions in mm C 108,5 108,5 108,5 D 27 27 27 E 15 15 15

266,5 266,5 266,5

B C

Options and Accessories

Guide rings for all tube and pipe O.D.s TIG Hot Wire version for highest deposition rates Extension cable (15 m) Compact brief-case for transport and storage Tungsten electrodes, pre-sharpened and pre-cut Tool kit for daily operation On-board camera system

Adapting to all your applications !

Thanks to the automatic welding process we have the guarantee that our welding procedure is perfectly respected.

POLYCAR 60 PLC
TIG Cold Wire, Hot Wire, AV C , OSC

Open Type Carriage Welding Head for welding of tubes and pipes

THE ART OF WELDING

POLYCAR 60 PLC
Open Type Carriage Welding Head
for multipass TIG welding of tubes and pipes, especially in primary loop circuits in nuclear power plants
Highest flexibility and productivity

General Characteristics
Particularly designed for high duty cycle applications by means of high temperature resistant materials and closed loop water cooling Narrow Gap torch for root pass and filling, standard torch for weld finish Motorised Arc Voltage Control (AVC) and Torch Oscillation Control (OSC) for multipass welding of medium and heavy wall thicknesses Rotation clutch device for quick cable winding Low profile design for use in areas with constrained radial and axial clearance Integrated wire feeder with 5 kg (11 lbs) spool
Video container Finishing torch with camera Narrow Gaptorch with wire guide and integrated camera

Advantages
Orbital TIG carriage welding head (hot/cold wire) for tubes and pipes Perfectly adapted to tube and pipe welding of medium and heavy wall thicknesses, narrow gap welding up to 100 mm (3.9") groove depth The welding head travels around the tube on a premounted guide ring The full function welding head reproduces all motions of a skilled manual welder and completes the weld in a series of passes

Technical Specification
Outside diameter / Wall thickness Diameter range Maximum wall thickness Torches Finishing Torch Narrow Gap Torch Maximum travel speed Stroke Motor Manual offset slide Axial travel Radial travel Wire feeder Type Maximum wire feeding speed Spool weight / recommended wire diameter Polyfil 4800 HW 4800 mm/min - 189 in/min 5 kg - 11 lbs / 0,8 mm - 0.03" 15 m - 49.21 ft 12 kg - 26.5 lbs See drawings 30 mm - 1.2" 85 mm - 3.3" Conventional Narrow Gap 100 1500 mm/min - 59.1 in/min 60 mm - 2.4" Stepper motor
168 mm - 6.6"

Resulting from over 50 years experience in mastering welding technologies

100 mm - 3.9"

AVC (Arc Voltage Control) and OSC (Torch Oscillation Control)

Dimensions A 150 mm 378 mm 5.9" 14.9"

Dimensions and weight Cable length Weight (excl. cable) Dimensions of the welding head

Mechanical seam tracking

Associated Power Sources

P6 / P6 HW
300 to 520 A, all applications programming by PC or touch screen, with Arc Voltage Control (AVC) and Torch Oscillation Control (OSC), three-phase power supply

PC Series
300 to 600 A, modular design for perfect adaptation to your application. Interface for mechanised and robotic peripherals, three-phase power supply

Options and Accessories

Guide rings for all tube and pipe O.D.s Extension cable (15 m - 49.21 ft) Tungsten electrodes, pre-sharpened and pre-cut Tool kit for daily operation Compact shipping case for transport and storage Video container equipped with two monitors, recorder and control for two cameras

POLYCAR MP Multi-Process
TIG Cold Wire, Hot Wire, Plasma and MIG/MAG

Open Type Carriage Welding Head for welding of tube and pipe joints

THE ART OF WELDING

 Multi-Process

POLYCAR MP Open Type Carriage Welding Head

for welding of tube and pipe joints
High flexibility and increased productivity

General Characteristics
Motorised Arc Voltage Control (AVC) / stick-out and Torch Oscillation Control (OSC) for multi-pass welding

Advantages
Modular design for orbital TIG Cold Wire, Hot Wire, Plasma and MIG/MAG welding Perfectly adapted to tube and pipe welding of medium-sized and heavy wall thicknesses Reproduces all movements of a manual welder and completes the weld in a series of passes Especially designed for welding under difficult conditions in workshop or on site Narrow Gap Welding for further productivity increase Resulting from 50 years experience in mastering welding technologies

Only one 15 m umbilical between welding carriage and control unit

Torch module standard TIG

Particularly designed for high duty cycle applications by means of high temperature resistant materials and closed loop water cooling

Torch module V2 Narrow Gap for wall thicknesses up to 75 mm

Modular design for easy maintenance and job configuration

Encoder for position based control of the welding program: All position orbital 360 weld Uphill or downhill 2 x 180 weld with one or two simultaneously operating welding carriages

Torch module Narrow Gap for wall thicknesses up to 250 mm and more

Water cooled welding torch with quick coupling for the selected process

Torch module MIG/MAG with motorised torch inclination

Guide ring made from stainless steel or duplex for all tube and pipe O.D.s

Motorised or manual longitudinal torch inclination

On-board filler wire module for solid and flux cored wire, 5 kg spool

Associated Power Sources

P6
300 A, all applications, programming by PC or touch screen, with Arc Voltage Control (AVC) and Torch Oscillation Control (OSC), three-phase power supply

PC Series
300 to 600 A, modular design for perfect adaptation to your application. Interface for mechanised and robotic peripherals, three-phase power supply

MIG/MAG Container
Control unit for Polycar with interface allowing the use with standard power sources or synergic MIG/MAG

Torch module Plasma

Adapting to all your applications !

The flexibility of the system allowed us to choose the process most suited to our application.

Technical Specification
General characteristics Welding process Tube / pipe O.D. Welding method Welding movements Welding speed range Prepositioning Arc Voltage Control (AVC) or stick-out adjustment (stroke ; max. speed) Motorised longitudinal torch inclination (amplitude ; speed) Manual longitudinal torch inclination Manual lateral torch inclination Torch Oscillation Control (OSC) (stroke ; max. speed) Filler wire type Filler wire Wire feed speed Wire diameter (according to application) Spool Welding carriage weight (excluding cable) Others Welding torch duty cycle TIG Cold Wire, Hot Wire, MIG/MAG 168 mm / 6 " 360 , 2 x 180 downhill or uphill (with the torch inclination module) 30 to 1000 mm/min 2000 mm/min 69 mm; 2500 mm/min MIG/MAG TIG and MIG/MAG TIG 69 mm ; 2500 mm/min Solid wire, core wire TIG Cold Wire TIG Hot Wire MIG/MAG TIG MIG/MAG 200 mm, 5 kg 16 kg TIG Plasma MIG/MAG 400 A / 100 % 350 A / 100 % 465 A / 100 % 2,0 m/min 7,9 m/min 7,9 m/min (option 18 m/min) 0,8 ; 0,9 ; 1,0 mm 0,8 ; 1,0 ; 1,2 ; 1,4 ; 1,6 mm 35 ; 100 /min 20 25

Compatible with series of power sources

PS 406, P6, PC 300, PC 350 for TIG Cold Wire PC 600 for TIG Hot Wire / Plasma PC weld controller for MIG/MAG

TIG
B

Cable length: 15 m

Dimensions in mm TIG A B C D E F G 600 mm 450 mm 290 mm 120 mm 275 35 mm 40 mm 190 mm MIG/MAG 550 mm 450 mm 270 mm 120 mm 255 mm 45 mm 190 mm
D E D E F

MIG/MAG
B G A

C F

Options and Accessories

Guide ring made from stainless steel or duplex for all tupe and pipe O.D.s Motorised longitudinal torch inclination module for weld penetration control (pushing or dragging) Extension cable (15 m) Single macro connector and umbilical for TIG welding Compact shipping case for transport and storage

Solutions for Automated Cladding Operations

TIG Cold Wire, Hot Wire

used in the manufacturing and maintenance

THE ART OF WELDING

Solutions for Automated Cladding Operations

used in the manufacturing and maintenance

Horizontal Cladding

Featuring rotating workpiece or rotating torches

Advantages
Flexibility
For purposes of small and medium series production the system can be adapted to virtually any workpiece geometry
Rotating workpiece Rotating torch

Fields of application
Many industrial processes cause damage to piping and fittings by the continuous attack of corrosive and abrasive media. In oil and gas production for example, components are severely eroded by the friction of sand; chemical apparatuses suffer from direct contact with aggressive substances. These phenomena are often boosted by elevated process temperature and pressure. To increase the endurance of these highly exposed parts their surfaces are protected by cladding with better resisting materials. Cladding is applied whenever a long service life is expected from expensive components or the workpiece cannot be produced entirely from the proper wear-resistant material. Cladding of piping and fittings is common in applications in the petrochemical industry and for power plant equipment; in the aeronautic industry, components for aircraft engine components are also often reinforced using this process.

Universal application possibilities

During pre-fabrication in the shop or on site all welding positions are possible

Easy set-up
The system is composed of functional and reliable standard devices

Wide application range

Joining and cladding operations are carried out with the same equipment

User-friendly operation
Intuitive Human-Machine-Interface (HMI)

Quality assurance
100% repeatability and traceability of manufacturing

General Characteristics
The process
TIG-cladding, with Cold Wire or Hot Wire addition, is an arc welding process. The concentrated energy to melt the base and cladding material is released by an electric arc which is struck between the non-consumable tungsten electrode installed in the welding torch and the workpiece. Controlled melting of the base and cladding material leads to excellent metallurgical and mechanical properties in the finished workpiece, the protection of the heat affected zone is provided by complete purging of the area using argon. Several advantages are given by the cladding process developed by Polysoude: a very low dilution degree (3 to 10 %) between base and cladding material, a high deposition rate (up to 4 kg/h) and a very small heat affected zone. The specified geometry of the workpiece can be precisely obtained; reworking is reduced to a minimum thus allowing a considerable gain in time.

Application for small and medium series production

Turnkey cladding equipment proposed by Polysoude is suitable for all kinds of small and medium series production. Advice, carrying out of test welds, welding parameter development, support for commissioning and the initial production phase are already included in the scope of service.

Your turn-key equipment installation

No matter whether your cladding application can be better solved if the workpiece is rotating, or if the cladding torch turns, a wide choice of approved cladding tools and peripheral devices is available: collector-equipped cladding and welding heads allow endless rotation, Polysoude power sources control and synchronise all movements of a column and boom or a positioner perfectly. From the very beginning of the project your individual contact person at Polysoude is named; accompanying you during the specification of the equipment, the realisation of test welds, the fixing of the order, the training of your staff, and the commissioning and initial production phase.

Vertical Cladding

Featuring rotating workpiece or rotating torches

Rotating workpiece

Rotating torch

Adapting to all your applications !

A gain in quality of 40%

" These new installations allow a considerable reduction in weld cycle times for joining and cladding operations and an increase in productivity accordingly. In some factories, the deposition rate of Inconel Alloy625 was increased by 50 to 80%, at the same time the quality level was raised by 30 to 40%. The automatic process control provides the tools to respect specifications precisely, e.g. the degree of dilution can be kept reliably below 3% ".

Otto Henning Sulen / Subsea Services / Stavanger (Norway)

Technical Specification
Cladding process Base materials TIG - Cold Wire, Hot Wire X60, X65 and X70 as well as low-carbon steel F22, furthermore AISI 4150, 4140 and 8630 Inconel 52 , 52 M , 82 , 90 , Alloy C 22 , C 276 Duplex 22 % and 25 % Stainless steel 304 L , 308 L , 309 L , 316 L and 316 LSI Between 1.5 and 3 mm per layer 1- Between 3 and 10 %, the melting zone and the heat input are perfectly repeatable by the automatic process control Between 1,5 and 4 kg/h per torch, application of several cladding torches and multi-wire cladding are possible Cladding, buttering and joining ISO 9001 , ASME , DNV , IPE Aeronautic and aerospace industries, gas and oil production, petrochemical processing, construction and maintenance of power plants PC 600 Cold Wire, Hot Wire 15 - 600 A 465 A / 100 % 600 A / 60 % - Travel speed - Wire feeding - AVC (Arc Voltage Control) - OSC (Oscillation Control) - Synchronisation of peripheral devices (column and boom, positioner, etc.) Runs in Windows environment

Filler wire Thickness of cladding Number of layers realized consecutively by one or several cladding torches Degree of dilution Deposition rate Various torches Applicable standards and guidelines Industrial applications in the fields of manufacturing and maintenance Power source with integrated numerical control Welding current range Duty cycle Programmable and controlled units

Computer-aided Human-Machine-Interface (HMI) and welding software POW Welding data acquisition for total production monitoring

Options and Accessories

Cladding/welding torches and tools for various applications Kit of parts for transformation from cladding to joining Video monitoring system